Cast-in structure and cast-in mold for vehicle component

Abstract

A projection of burr is provided by forming an appropriate gap to set a cast-in member to a cast-in mold, completely closing the gap when the cast-in mold is clamped, and correcting cast-in positioning (axis mating) to a die-cast component by a clamping operation of the die-cast mold, regardless of a dimensional precision of the cast-in member upon a manufacture. Steel plate cast-in member 2, wrapped cast except for a bonding portion 2b to a steel plate bonding member 3 upon molding a die-cast component 1, has a mold contact portion 4 at a boundary between a cast-in portion 2a wrapped cast with a die-cast component 1 and the bonding portion 2b. When a cast-in mold A is clamped, the mold contact portion 4 is brought into butting contact with the cast-in mold A, gap S between the cast-in member 2 and the cast-in mold A, cavity a, is closed.

The invention claimed is: 
     
       1. A method of forming a cast-in structure with a cast-in member, wherein the cast-in member is made of a steel plate having a cast-in portion, a bonding portion to be bonded to a steel plate bonding member, and mold contact portions on both of opposite side surfaces of the cast-in member at a boundary between the cast-in portion and the bonding portion, the method comprising:
 clamping a cast-in mold around the cast-in portion of the cast-in member so that the mold contact portion of the cast-in member is in intimate butting contact with the cast-in mold on both of the opposite side surfaces of the cast-in member; 
 molding a die-cast component in the cast-in mold within which the cast-in portion of the cast-in member is wrapped cast with a wrapped casting excluding the bonding portion from the wrapped casting; 
 
       wherein the mold contact portion of the cast-in member is formed to have a taper shape; 
       wherein the cast-in mold has a structure including a fixed mold, a movable mold that can perform mold clamping and mold opening relative to the fixed mold, and a movable core that is assembled to the movable mold so as to be capable of advancing and retreating and forms a cavity with both of the fixed mold and the movable mold; and
 the mold contact portion of the cast-in member is in intimate butting contact with the fixed mold and the movable mold at the outside of the mold contact portion, and the mold contact portion of the cast-in member is intimate butting contact with the movable core at the inside of the mold contact portion. 
 
     
     
       2. The method according to  claim 1 , wherein:
 the cast-in member is formed into a hollow cylinder; 
 the mold contact portions comprise internal and external mold contact taper surface portions, formed to have a taper shape in an axial direction of the cylinder and formed around the entire circumference of the cylinder; 
 the boundary is a boundary between the bonding portion at one end of the cast-in member and the cast-in portion on both inside and outside surfaces at the other end of the cast-in member; 
 the method further comprising clamping the cast-in mold comprises bringing a tapered butting portion formed on the cast-in mold into intimate butting contact with the internal and external mold contact taper surface portions.